CN117957361A - Coating system for coating a substrate and method for coating a substrate using the same - Google Patents
Coating system for coating a substrate and method for coating a substrate using the same Download PDFInfo
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- CN117957361A CN117957361A CN202280061518.9A CN202280061518A CN117957361A CN 117957361 A CN117957361 A CN 117957361A CN 202280061518 A CN202280061518 A CN 202280061518A CN 117957361 A CN117957361 A CN 117957361A
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- 239000000758 substrate Substances 0.000 title claims abstract description 138
- 238000000576 coating method Methods 0.000 title claims abstract description 65
- 239000011248 coating agent Substances 0.000 title claims abstract description 63
- 238000000034 method Methods 0.000 title claims abstract description 15
- 239000011343 solid material Substances 0.000 claims abstract description 61
- 238000012546 transfer Methods 0.000 claims abstract description 61
- 230000007246 mechanism Effects 0.000 claims abstract description 51
- 238000005303 weighing Methods 0.000 claims abstract description 41
- 239000000463 material Substances 0.000 claims description 52
- 238000011068 loading method Methods 0.000 claims description 20
- 238000005259 measurement Methods 0.000 claims description 13
- 239000002699 waste material Substances 0.000 claims description 8
- 238000004891 communication Methods 0.000 claims description 6
- 238000002156 mixing Methods 0.000 claims description 4
- 238000012360 testing method Methods 0.000 claims description 3
- 239000007789 gas Substances 0.000 description 31
- 238000010586 diagram Methods 0.000 description 5
- 238000001914 filtration Methods 0.000 description 4
- 230000003197 catalytic effect Effects 0.000 description 3
- 239000004071 soot Substances 0.000 description 3
- 238000009530 blood pressure measurement Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 239000013618 particulate matter Substances 0.000 description 2
- 238000010926 purge Methods 0.000 description 2
- 230000007723 transport mechanism Effects 0.000 description 2
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000003345 natural gas Substances 0.000 description 1
- 238000013021 overheating Methods 0.000 description 1
- 239000000779 smoke Substances 0.000 description 1
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
- F01N3/033—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices
- F01N3/035—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices with catalytic reactors, e.g. catalysed diesel particulate filters
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2510/00—Surface coverings
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2560/00—Exhaust systems with means for detecting or measuring exhaust gas components or characteristics
- F01N2560/07—Exhaust systems with means for detecting or measuring exhaust gas components or characteristics the means being an exhaust gas flow rate or velocity meter or sensor, intake flow meters only when exclusively used to determine exhaust gas parameters
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2560/00—Exhaust systems with means for detecting or measuring exhaust gas components or characteristics
- F01N2560/08—Exhaust systems with means for detecting or measuring exhaust gas components or characteristics the means being a pressure sensor
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Health & Medical Sciences (AREA)
- Toxicology (AREA)
- Coating Apparatus (AREA)
Abstract
The invention provides a coating system for coating a substrate (10), comprising a dosing unit (1) for pre-weighing a solid material to be transported; -a conveying unit (2) for conveying the weighed solid material to the substrate (10) to be coated by a conveying gas flow; -a receiving unit (3) for receiving the substrate (10) and located downstream of the conveying unit (2) in the flow direction (F) of the conveying gas flow; -an automatic transfer mechanism (4) for transferring the substrate (10) to the receiving unit (3) and removing the coated substrate (10) from the receiving unit (3); a control unit (5) for controlling the operations of the dosing unit (1), the receiving unit (3) and the automatic transfer mechanism (4); and a gas flow generating device (20) for generating the transport gas flow. The invention also relates to a method for coating a substrate (10) using said coating system.
Description
Technical Field
The present invention relates to a coating system for coating a substrate, in particular for a wall-flow filter, and a method for coating a substrate using the coating system.
Background
Certain internal combustion engines, such as lean-burn engines, diesel engines, natural gas engines, power plants, incinerators, and gasoline engines, tend to produce exhaust gas with significant amounts of smoke and other particulate matter. Generally, particulate emissions may be remedied by passing exhaust gas containing PM through a wall-flow filter.
Diesel wall-flow filters have proven to be effective in removing soot from the exhaust of diesel engines. The most widely used diesel particulate filter is a wall-flow filter that filters diesel exhaust by trapping soot on the porous walls of the filter body. Wall-flow filters are designed to provide near complete filtration of soot without significantly impeding exhaust flow.
There is a need to provide an improved coating system and coating method to obtain filters, such as wall-flow filters, with excellent filtration efficiency and low back pressure.
Recently, even stricter regulations, such as european 6d and chinese 6b, have been implemented, and conventional catalytic filter technologies cannot meet both the particulate emission target of customers and the backpressure target of exhaust systems without further improvement. This creates an urgent need to develop next generation catalytic filters (or FWCs) and at the same time develop a new coating system capable of mass-producing the next generation products.
Disclosure of Invention
It is an object of the present invention to provide an improved coating system for more efficient production of filters with excellent filtration efficiency and low back pressure.
It is another object of the present invention to provide an improved coating method for more efficiently preparing filters with excellent filtration efficiency and low back pressure.
Accordingly, one aspect of the present invention relates to a coating system for coating a substrate, the coating system comprising: a quantifying unit for pre-weighing the solid material to be conveyed; a conveying unit for conveying the weighed solid material to the substrate to be coated by a conveying gas flow; a receiving unit for receiving the substrate and located downstream of the conveying unit in a flow direction of the conveying gas flow; an automatic transfer mechanism for transferring the substrate to the receiving unit and removing the coated substrate from the receiving unit; a control unit for controlling operations of the dosing unit, the receiving unit and the automatic transfer mechanism; and a gas flow generating device for generating a transport gas flow.
In embodiments, the dosing unit may include an automatic material dosing device having a material container with a dispensing port and a dispensing mechanism disposed in the material container; a material transfer container; a weighing device; wherein the dispensing mechanism is for dispensing solid material into the material transfer container through the dispensing port and the weighing device is for weighing the solid material in the material transfer container.
In an embodiment, the dispensing mechanism and the weighing device may be in communication with a control unit, respectively, and the control unit receives a weight measurement of the solid material dispensed into the material transfer container from the weighing device and compares the weight measurement with a set weight of the solid material to be conveyed, and if the weight measurement is within + -5% of the set weight, the control unit will control the dispensing mechanism to stop dispensing the solid material.
In an embodiment, the delivery unit may comprise a delivery tube comprising a first cylindrical tube segment, a second conical tube segment, and a third cylindrical tube segment connected in sequence; wherein the second cylindrical tube section is movably connectable to the first cylindrical tube section such that the second cylindrical tube section is movable relative to the first cylindrical tube section between a first position in which the third cylindrical tube section is capable of being lowered to be air-tightly connected with the receiving unit and to cover the substrate, and a second position in which the third cylindrical tube section is capable of being raised to leave sufficient space for the automated transfer mechanism to operate the substrate to be coated or the coated substrate.
Preferably, the conveying pipe may be arranged vertically and may further comprise a first conical pipe section connected to the first cylindrical pipe section for receiving the weighed solid material; wherein the first conical tube section converges in the flow direction of the conveying gas flow and the second conical tube section diverges in the flow direction of the conveying gas flow.
In embodiments, the length of the second cylindrical tube segment may be less than the length of the first cylindrical tube segment; the diameter (inner diameter) of the second cylindrical tube section may be smaller than the diameter (inner diameter) of the first cylindrical tube section; and the diameter and height of the third cylindrical tube section may be selected such that the third cylindrical tube section may cover the substrate to be coated.
Preferably, the inner diameter of the first cylindrical tube section is defined as D. The diameter of the second cylindrical tube section is smaller than the diameter of the first cylindrical tube section, for example 2mm to 5mm, such as 3mm, smaller than the diameter of the first cylindrical tube section. The height of the second conical tube section may be in the range of 0.5D to 1.5D. The height of the third cylindrical tube section may be 1.2D to 1.8D, for example 1.5D. The diameter of the third cylindrical tube section is selected to be in the range of 2.5D to 3D. In embodiments, the diameter of the third cylindrical tube section is greater than the diameter of the circular cross section of the substrate, or, in the case of an elliptical cylinder, the minor axis of the elliptical cross section of the substrate.
Preferably, the diameter of the first cylindrical tube section may be in the range of 40mm to 140 mm. The diameter of the second cylindrical tube section is 2mm to 5mm smaller than the diameter of the first cylindrical tube section. The height of the second conical tube section may be in the range of 20mm to 200 mm. The height of the third cylindrical tube section may be in the range of 60mm to 200 mm. The diameter of the third cylindrical tube section is selected to be in the range of 100mm to 400 mm.
In an embodiment, the receiving unit may comprise a holding mechanism for fixedly holding the substrate, and a connecting line for hermetically connecting the holding mechanism and the substrate to the gas flow generating device, wherein the pressure sensor and the flow sensor are arranged in the connecting line.
Preferably, the gas flow generating means may be a fan arranged downstream of the receiving unit to generate a flow of conveying gas flowing from the inlet end of the conveying pipe to the outlet end of the conveying pipe; and the cooler is also arranged in the connecting line close to the fan.
Preferably, the holding mechanism is an inflatable flexible holder that can be adjusted to hold substrates of different sizes; and the control unit is in communication with the pressure sensor and the flow sensor to receive the gas flow and pressure measured in the connecting line by the pressure sensor and the flow sensor; wherein the cross section of the connecting pipeline is larger than the cross section of the base material.
In an embodiment, the substrate may be a filter substrate, in particular a wall flow filter substrate having an inlet side and an outlet side, and the substrate is arranged in an inflatable flexible holder, wherein the inlet side of the substrate faces the transport unit. Wherein in the first position the third cylindrical tube section is capable of being lowered to be air tightly connected to the holding means.
In an embodiment, the coating system further comprises: a loading table on which at least two combinations of a conveying unit and a receiving unit are arranged; a feeding device arranged on one side of the automatic transfer mechanism near the loading table; and an output device disposed on the other side of the automatic transfer mechanism near the loading table.
Preferably, the loading table is a circular arc table, and at least two combinations are mounted on the loading table in a circumferential direction of the circular arc; wherein the automatic transfer mechanism is arranged at the center of the circular arc such that the distance from the automatic transfer mechanism to each receiving unit is the same.
More preferably, the loading table is a semicircular table, and four combinations of a conveying unit and a receiving unit are arranged on the loading table, wherein the automatic transfer mechanism is a robot that communicates with the control unit, and the control unit controls the robot to determine which receiving unit is in an idle state, and then transfers the substrate to be coated to the idle receiving unit.
In embodiments, the output device may include at least two output conveyors, one of the output conveyors may be for good products and the other of the output conveyors may be for bad products.
Preferably, the coating system may further comprise a back pressure measuring device which can be used to measure the back pressure of the substrate to be coated, such that the weight of the solid material to be coated on the substrate can be determined based on the measured back pressure value.
Another aspect of the invention relates to a method of coating a substrate using the coating system described above, the method comprising the steps of: providing a substrate; transferring the substrate to the receiving unit by an automatic transfer mechanism, and fixedly holding the substrate in the receiving unit; pre-weighing a solid material to be coated on a substrate by a dosing unit; mixing the weighed solid materials with a flow of conveying gas and conveying them to a receiving unit by a conveying unit to coat the substrate; and removing the coated substrate from the receiving unit by an automated transfer mechanism.
Advantageously, in the step of pre-weighing the solid material to be coated on the substrate by the dosing unit, the total weight of the material transfer container measured by the weighing device and the solid material to be conveyed in the material transfer container is defined as Wt, the material transfer container is re-weighed by the weighing device after feeding the solid material in the material transfer container into the conveying unit, and the measured value is Wr, then Wt-Wr is the actual material weight G fed to the conveying unit; if the actual material weight G is within the set weight w±5%, the dosing unit will continue to weigh the solid material for the next substrate, otherwise the weighing device 16 will send a signal to the control unit to mark the now coated substrate as "waste product".
Preferably, after the step of removing the coated substrate from the receiving unit, the obtained product may be judged to be acceptable by a backpressure test. For example, if the back pressure of the desired product is P, and the measured back pressure pt=p (1±5%), the product may be judged as a good product, otherwise the product may be judged as a bad product (waste product).
Preferably, the method further comprises the step of measuring the back pressure of the substrate to be coated by a back pressure measuring device before the pre-weighing step, and determining the weight of the solid material to be coated on the substrate based on the back pressure measurement.
The coating system according to the present invention is capable of meeting both the particulate emission objective of the customer and the backpressure objective of the exhaust system without further improvement. The product (catalytic filter) obtained by the novel coating system has a higher particulate matter capturing efficiency, and at the same time the coating system enables mass production of the product.
Drawings
FIG. 1 shows a schematic block diagram of one embodiment of a coating system according to the present invention;
fig. 2 shows a schematic block diagram of a dosing unit according to the invention;
Fig. 3 is a schematic structural view showing a transmitting unit and a receiving unit;
FIG. 4 is a schematic block diagram of a loading station, a feed device, and an output device; and
Fig. 5 is a schematic block diagram of an embodiment of a substrate for a wall-flow filter according to the present invention.
Detailed Description
The undefined articles "a", "an", "the" and "said" refer to one or more of the species specified by the term following the article.
In the context of the present disclosure, any particular value mentioned for a feature (including the particular values mentioned in the ranges as endpoints) may be recombined to form a new range.
In the context of the present disclosure, each aspect so defined may be combined with any other aspect or aspects unless clearly indicated to the contrary. In particular, any feature indicated as being preferred or advantageous may be combined with any other feature or features indicated as being preferred or advantageous.
Fig. 1 shows a schematic block diagram of one embodiment of a coating system for coating a substrate 10 according to the present invention. The coating system mainly includes a dosing unit 1, a conveying unit 2, a receiving unit 3, an automatic conveying mechanism 4, and a control unit 5 for controlling operations of the dosing unit 1, the receiving unit 3, and the automatic conveying mechanism 4. The dosing unit 1 is for pre-weighing and dosing solid material to be transported, the transport unit 2 is for transporting the weighed solid material to the substrate 10 to be coated by means of a transport gas flow, and an automatic transport mechanism 4 is provided for transporting the substrate 10 to be coated to a receiving unit and removing the coated substrate from the receiving unit. Furthermore, the receiving unit 3 is for receiving the substrate and is located downstream of the conveying unit in the flow direction F of the conveying gas flow. The coating system may further comprise a gas flow generating device 20 for generating a transport gas flow. In the present invention, the substrate may be a substrate for a particulate filter, in particular for a wall-flow filter. However, it will be appreciated by those skilled in the art that the substrate may be other types of substrates that need to be coated.
As shown in fig. 2, in a preferred embodiment, the dosing unit 1 may comprise an automatic material dosing device 11, a material transfer container 15 and a weighing device 16. As can be seen in the figures, the automatic material dosing device 11 is configured to comprise a material container 13 with a dispensing port (or dispensing tube) 12 and a dispensing mechanism 14 arranged in the material container. The solid material to be conveyed is contained in a material container and a dispensing mechanism 14 is used to dispense the solid material through a dispensing port 12 into a material transfer container 15, such as a cup, and the solid material in the material transfer container is weighed by a weighing device. In an example, the dispensing mechanism 14 may be, for example, a threaded screw mechanism for pushing solid material into a diagonally arranged dispensing tube.
In the above-described dosing unit 1, the dispensing mechanism 14 and the weighing device 16 are respectively in communication with the control unit 4, and the control unit 4 receives a weight measurement value W1 of the solid material dispensed into the material conveying container from the weighing device 16, and compares the weight measurement value W1 with a set weight W of the solid material to be conveyed, and if the weight measurement value W1 is within a range of the set weight w±5%, the control unit 4 will control the dispensing mechanism 14 to stop dispensing the solid material. In actual operation, the weight measurement W1 of the solid material is the weight measurement Wt of the weighing device 16 minus the weight Wc of the material transfer container 15. Since it is difficult to avoid some solid material adhering to the walls of the material transfer container 15, after feeding the solid material in the material transfer container 15 into the conveying unit 2, it is necessary to put the empty material transfer container 15 on the weighing device 16 for re-weighing, and the measured value is Wr, then Wt-Wr is the actual material weight G fed into the conveying unit 2. If the actual material weight G is within a specified range, e.g. within a set weight w±5%, the dosing unit 1 will continue to weigh the solid material for the next substrate, otherwise the weighing device 16 will send a signal to the control unit to mark the now coated substrate as "waste product".
As shown in fig. 3, in an embodiment according to the present invention, the delivery unit 2 comprises a vertically oriented delivery tube 21, which may comprise a first conical tube section 211, a first cylindrical tube section 212, a second cylindrical tube section 213, a second conical tube section 214 and a third cylindrical tube section 215, connected in sequence. Advantageously, the second cylindrical tube segment 213 is movably connected to the first cylindrical tube segment 212 such that the second cylindrical tube segment 213 can be moved relative to the first cylindrical tube segment 212 between a first position in which the third cylindrical tube segment 215 can be lowered to be connected airtight with the receiving unit 3 and cover the substrate 20 to be coated, and a second position in which the third cylindrical tube segment 215 can be raised to leave sufficient space for the automated transport mechanism 4 to operate the substrate to be coated or the coated substrate. The manner of connection between the second cylindrical tube segment 213 and the first cylindrical tube segment 212 is known to those skilled in the art and will not be repeated here.
In this embodiment, the first conical tube section 211 is used to receive the weighed solid material from the material transfer container 15 and preferably converges in the flow direction F of the conveying gas flow, so that the solid material from the material transfer container 5 is more easily fed into the transfer tube. It should be appreciated that the first tapered tube section 211 is optional or can be omitted. Furthermore, in the present application, the cylindrical tube sections herein may be replaced with tube sections having other cross-sections, such as square cross-sections, which are also within the scope of the present application. Further, in the present application, the second conical tube section 214 is configured to gradually expand in the flow direction F of the conveying gas flow.
In the embodiment shown in fig. 3, the length of the second cylindrical tube segment 213 may be less than the length of the first cylindrical tube segment 212. Further, for example, the (inner) diameter D of the first cylindrical tube section 212 may be selected to be 40mm to 140mm, preferably 60mm to 100mm, and more preferably 60mm or 100mm. The (inner) diameter of the second cylindrical tube section 213 is smaller than the diameter of the first cylindrical tube section 212, e.g. 2mm to 5mm smaller than the diameter of the first cylindrical tube section 212, so that the second cylindrical tube section is free to move in the first cylindrical tube section. The diameter and height of the third cylindrical tube section 215 should be selected to be capable of covering the substrate 10 to be coated. For example, the height of the third cylindrical tube segment 215 may be 1.2D to 1.8D, such as 1.5D. In particular, the height of the third cylindrical tube section may be in the range of 60mm to 200mm, preferably in the range of 90mm to 150mm, for example 90mm or 150mm. Further, the diameter of the third cylindrical tube segment 215 may be in the range of 2.5D to 3D. In particular, the diameter of the third cylindrical tube segment 215 may be in the range of 100mm to 400mm, preferably in the range of 150mm to 300mm, such as 150mm or 300mm. In this case, the diameter of the third cylindrical tube section is greater than the diameter of the circular cross section of the substrate or, in the case of an elliptical cylinder, the minor axis of the elliptical cross section of the substrate.
Furthermore, during operation of the coating system, the diameters of the first cylindrical tube section 212 and the second cylindrical tube section 213, as well as the heights of the second conical tube section 214 and the third cylindrical tube section 215, are very important for the distribution of the solid material coated on the substrate. Particularly for the height of the second conical tube section 214, the greater the height value thereof, turbulence will be created in the chamber defined by the first cylindrical tube section 214 and the better the distribution of the solid material will be. For example, the height of the second conical tube section may be in the range of 20mm to 200mm, preferably in the range of 100mm to 200 mm.
According to an embodiment of the invention, with further reference to fig. 3, the receiving unit 3 may comprise a holding means 31 for fixedly holding the substrate 10 to be coated, and the holding means may be connected to the gas flow generating device 20 gas-tightly by means of a connecting line 32 having a cross section larger than the cross section of the substrate 10. For example, the gas flow generating means 20 may be a fan arranged downstream of the receiving unit 3 to generate a flow of conveying gas flowing from the inlet end 21a of the conveying pipe to the outlet end 21b of the conveying pipe. Advantageously, the holding mechanism 31 is an expandable flexible holder that can be adjusted to hold substrates 10 of different sizes. For example, the inflatable flexible holder may be in the form of a swim ring or a tire.
To prevent overheating of the fan, a cooler (not shown) may be provided in the connecting line 32 close to the fan. In addition, a gas buffer tank (not shown) may be connected to the connection line in order to maintain stability of the flow of the conveying gas. In addition, a pressure sensor 33 and a flow sensor 34 are provided in the connection line, and the control unit 5 communicates with the pressure sensor 33 and the flow sensor 34 to receive the gas flow and pressure measured in the connection line by the pressure sensor and the flow sensor so as to monitor the pressure and the gas flow in the connection line 32 in real time to control the back pressure stability of the substrate.
Further, a branch pipe (not shown) capable of bringing the connection pipe 32 into fluid communication with the outside environment may be disposed near the cooler, and a control valve may be disposed in the branch pipe, and the control valve may be fully or partially opened when the coating system is operated, so as to control the flow rate of the conveying air flow in the conveying unit 2.
As shown in fig. 4, according to the embodiment of the present invention, the coating system includes a loading stage 6, which is a semicircular stage, and the automatic transfer mechanism 4 is disposed at the center of the semicircular arc such that the distance from the automatic transfer mechanism to each receiving unit is the same. The coating system further comprises a feeding device 7 arranged on one side of the automatic transfer mechanism 4 close to the loading table 6 and an output device 8 arranged on the other side of the automatic transfer mechanism 4 close to the loading table 6.
It will be appreciated by those skilled in the art that the loading table of the present application may be configured in other suitable shapes, for example, other arcs than semi-circles, which are also within the scope of the present application. In the present embodiment, four combinations of the conveying unit 2 and the receiving unit 3 may be arranged on the loading table. For simplicity, only the containing units 3 in the combination are shown in fig. 4. Here, the automatic transfer mechanism 4 is a robot that communicates with the control unit 5, and the control unit controls the robot to determine which receiving unit is in an idle state and then transfers the substrate to be coated to the idle receiving unit.
In an embodiment according to the invention, the output device 8 may comprise at least two output conveyors, one of which may be used for good products and the other of which may be used for bad products.
For example, in the embodiment shown in fig. 4, the output conveyor 8 may include three output conveyors 81, 82, 83, one of the output conveyors 81 for reject product and the other two output conveyors 82, 83 for reject product at different back pressure ranges.
Preferably, the coating system can also comprise a back pressure measuring device 9 which can measure the back pressure of the substrate to be coated, so that the weight of the solid material to be coated on the substrate can be determined based on the measured back pressure value.
In the present invention, referring to fig. 5, the substrate 10 is, for example, a wall-flow filter substrate and has an inlet side 10a and an outlet side 10b, wherein the substrate 10 is arranged in an inflatable flexible holder, wherein the inlet side 10a of the substrate faces the transport unit 2, in other words wherein the inlet side 10a of the substrate faces the connecting line 22. When the cylindrical tube segment 213 is in the first position, the third cylindrical tube segment 215 can be lowered to be hermetically connected to the expandable flexible retainer. The substrate shown in fig. 5 has a circular cross section, and the diameter of the cross section of the substrate having a relatively small size may be in the range of 95mm to 155mm, while the diameter of the cross section of the substrate having a relatively large size may be in the range of 160mm to 350mm, for example. In an embodiment not shown, the cross-section of the substrate may be elliptical, in which case the minor axis of the elliptical cross-section of the substrate having a relatively small size may be in the range of 95mm to 155mm, while the minor axis of the cross-section of the substrate having a relatively large size may be in the range of 160mm to 350mm, for example.
The invention also relates to a method for coating a substrate 10 using the coating system described above to obtain a product such as a wall-flow filter, the method comprising the steps of: providing a substrate 10; the substrate is conveyed to the receiving unit 3 by the automatic conveying mechanism 4, and is fixedly held in the receiving unit; pre-weighing a solid material to be coated on a substrate by a dosing unit 1; mixing the weighed solid materials with a flow of conveying gas and conveying them by a conveying unit to a receiving unit 3 for coating the substrate; and the coated substrate is removed from the receiving unit 3 by the automatic transfer mechanism 4.
In the step of providing the substrate 10, a scanning device (not shown) may be provided to scan the provided substrate to determine whether the batch of substrates are correct. If correct, the substrate will be fixed and held in the receiving unit 3, otherwise the substrate will be judged as a waste substrate.
In the step of pre-weighing the solid material to be coated on the substrate by the dosing unit 1, it is also possible to measure the weight G of the solid material actually fed into the conveying unit 2 by the weighing device 16 and send this weight to the control unit for comparison with the set weight W. In particular, the total weight of the material transfer container 15 and the solid material to be conveyed in the material transfer container measured by the weighing device 16 is defined as Wt, the material transfer container 15 is re-weighed by the weighing device 16 after feeding the solid material in the material transfer container 15 to the conveying unit 2, and the measured value is Wr, then Wt-Wr is the actual material weight G fed to the conveying unit 2; if the actual material weight G is within the set weight w±5%, the dosing unit 1 will continue to weigh the solid material for the next substrate, otherwise the weighing device 16 will send a signal to the control unit to mark the now coated substrate as "waste product".
In the step of mixing the weighed solid materials with the transport gas stream and transporting them to the receiving unit 3 by the transporting unit 2 to coat the substrate, the flow rate of the transport gas stream may be controlled. In order to give the obtained product acceptable product characteristics and appearance, substrates of different dimensions can be provided with transport gas streams having different flow rates. Furthermore, during coating, it is necessary to purge the substrate to be coated with a flow of transport gas having a suitable flow rate for a certain period of time, such as 20 seconds. If the flow rate is not appropriate and the purge time is insufficient, the product obtained will be unacceptable.
After the step of removing the coated substrate from the receiving unit 3, it is possible to judge whether the obtained product is acceptable or not by a back pressure test. For example, if the back pressure of the desired product is P, and the measured back pressure pt=p (1±5%), the product may be judged as a good product, otherwise the product may be judged as a bad product (waste product).
Preferably, the above method further comprises the step of measuring the back pressure of the substrate to be coated by a back pressure measuring device before the pre-weighing step, and determining the weight of the solid material to be coated on the substrate based on the back pressure measurement.
Various modifications and changes may be made to the embodiments disclosed above, as will occur to those skilled in the art, without departing from the scope or spirit of the disclosure. Other embodiments will be apparent to those skilled in the art in light of this disclosure. The specification and examples of the disclosure are to be considered merely as illustrative, and the scope of the disclosure is to be indicated by the appended claims and their equivalents.
Claims (21)
1. A coating system for coating a substrate (10), the coating system comprising:
A dosing unit (1) for pre-weighing a solid material to be conveyed;
-a conveying unit (2) for conveying the weighed solid material to the substrate (10) to be coated by a conveying gas flow;
-a receiving unit (3) for receiving the substrate and located downstream of the conveying unit in a flow direction (F) of the conveying gas flow;
An automatic transfer mechanism (4) for transferring the substrate to the receiving unit and removing the coated substrate from the receiving unit;
a control unit (5) for controlling the operation of the dosing unit (1), the receiving unit (3) and the automatic transfer mechanism (4); and
-A gas flow generating device (20) for generating the transport gas flow.
2. Coating system according to claim 1, wherein the dosing unit (1) comprises:
an automatic material dosing device (11) comprising a material container (13) having a dispensing port (12) and a dispensing mechanism (14) arranged in the material container;
a material transfer container (15); and
A weighing device (16);
Wherein the dispensing mechanism (14) is for dispensing the solid material into the material transfer container (15) through the dispensing port (12), and the weighing device is for weighing the solid material in the material transfer container.
3. The coating system of claim 2, wherein,
The dispensing mechanism (14) and the weighing device (16) are in communication with the control unit (5), respectively, and the control unit (5) receives a weight measurement of the solid material dispensed into the material transfer container from the weighing device (16) and compares the weight measurement with a set weight of the solid material to be conveyed, and if the weight measurement is within + -5% of the set weight, the control unit (5) will control the dispensing mechanism (14) to stop dispensing the solid material.
4. The coating system according to claim 1 to 3, wherein,
The conveying unit (2) comprises a conveying pipe (21) which comprises a first cylindrical pipe section (212), a second cylindrical pipe section (213), a second conical pipe section (214) and a third cylindrical pipe section (215) which are connected in sequence;
Wherein the second cylindrical tube section (213) is movably connected to the first cylindrical tube section (212) such that the second cylindrical tube section is movable relative to the first cylindrical tube section (212) between a first position in which the third cylindrical tube section (215) is able to descend to be connected with the receiving unit (3) gas-tightly and cover the substrate, and a second position in which the third cylindrical tube section (215) is able to ascend to leave sufficient space for the automatic transfer mechanism to operate the substrate to be coated or the coated substrate.
5. The coating system of claim 4, wherein,
The conveying pipe (21) is vertically oriented and further comprises a first conical pipe section (211) connected to the first cylindrical pipe section (212) for receiving the weighed solid material;
Wherein the first conical tube section (211) converges in the flow direction (F) of the transport gas flow and the second conical tube section (214) diverges in the flow direction of the transport gas flow.
6. The coating system of claim 5, wherein,
-The second cylindrical tube section (213) has a length smaller than the length of the first cylindrical tube section (212);
-the diameter of the second cylindrical tube section (213) is smaller than the diameter of the first cylindrical tube section (212); and
The diameter and height of the third cylindrical tube section (215) are selected such that the third cylindrical tube section can cover the substrate (10) to be coated.
7. The coating system according to any one of claims 4 to 6, wherein,
The inner diameter of the first cylindrical tube section (212) is defined as D;
-the inner diameter of the second cylindrical tube section (213) is 2mm to 5mm smaller than the inner diameter of the first cylindrical tube section (212);
the height of the second conical tube section (214) is in the range of 0.5D to 1.5D;
the height of the third cylindrical tube section (215) is in the range of 1.2D to 1.8D; and
-Said diameter of said third cylindrical tube section (215) is in the range of 2.5D to 3D;
Wherein the diameter of the third cylindrical tube section (215) is greater than the diameter of the circular cross section of the substrate or, in the case of an elliptical cylinder, the minor axis of the elliptical cross section of the substrate.
8. The coating system according to any one of claims 4 to 7, wherein,
The first cylindrical tube section (212) has an inner diameter in the range of 40mm to 140 mm;
-the inner diameter of the second cylindrical tube section (213) is 2mm to 5mm smaller than the inner diameter of the first cylindrical tube section (212);
the height of the second conical pipe section is in the range of 20mm to 200 mm;
-the height of the third cylindrical tube section (215) is in the range of 60mm to 200 mm; and
The diameter of the third cylindrical tube section (215) is in the range of 100mm to 400 mm.
9. The coating system according to any one of claims 1 to 8, wherein the receiving unit (3) comprises:
a holding mechanism (31) for fixedly holding the base material (10); and
-A connecting line (32) for hermetically connecting the holding means and the substrate to the gas flow generating device (20);
Wherein a pressure sensor (33) and a flow sensor (34) are arranged in the connecting line.
10. Coating system according to claim 9, wherein the gas flow generating means (20) is a fan arranged downstream of the receiving unit (3) to generate the transport gas flow from the inlet end (21 a) of the transport pipe to the outlet end (21 b) of the transport pipe; and a cooler is also arranged in the connecting line (32) close to the fan.
11. The coating system according to claim 9, wherein the holding mechanism (31) is an expandable flexible holder that can be adjusted to hold different sizes of the substrate; and the control unit (5) communicates with the pressure sensor (33) and the flow sensor (34) to receive the gas flow and pressure measured in the connecting line by the pressure sensor and the flow sensor;
Wherein the cross section of the connecting line (32) is larger than the cross section of the base material (10).
12. The coating system according to claim 11, wherein the substrate (10) is a substrate for a wall-flow filter and has an inlet side (10 a) and an outlet side (10 b), and the substrate (10) is arranged in the expandable flexible holder with the inlet side (10 a) of the substrate facing the transport unit (2); and
Wherein in the first position, the third cylindrical tube segment (215) is lowerable to be hermetically connected to the expandable flexible retainer.
13. The coating system of any one of claims 1 to 12, further comprising:
A loading table (6) on which at least two combinations of the conveying unit (2) and the receiving unit (3) are arranged;
-a feeding device (7) arranged on one side of the automatic transfer mechanism (4) close to the loading table (6); and
-An output device (8) arranged on the other side of the automatic transfer mechanism (4) close to the loading table (6).
14. Coating system according to claim 13, wherein the loading table (6) is a circular arc table and the at least two combinations are mounted on the loading table in the circumferential direction of the circular arc;
wherein the automatic transfer mechanism (4) is arranged at the center of the circular arc such that the distance from the automatic transfer mechanism to each receiving unit is the same.
15. Coating system according to claim 14, wherein the loading station (6) is a semi-circular station and four combinations of the conveying unit and the receiving unit are arranged on the loading station, wherein the automatic transfer mechanism (4) is a robot in communication with the control unit (5) and the control unit controls the robot to determine which receiving unit is in an idle state and then transfer the substrate to be coated to the idle receiving unit.
16. Coating system according to any one of claims 13 to 15, wherein the output device (8) comprises at least two output conveyors, one (81) of which is for good products and the other (82) of which is for bad products.
17. The coating system according to any one of claims 1 to 16, further comprising a back pressure measuring device operable to measure the back pressure of the substrate to be coated, such that the weight of the solid material to be coated on the substrate can be determined based on the measured back pressure value.
18. A method of coating a substrate (10) using the coating system according to any one of claims 1 to 17, the method comprising:
-providing the substrate (10);
-transferring the substrate to a receiving unit (3) by means of an automatic transfer mechanism (4) and fixedly holding the substrate in the receiving unit;
Pre-weighing a solid material to be coated on the substrate by means of a dosing unit (1);
Mixing the weighed solid materials with the transport gas stream and transporting them by the transport unit to the receiving unit (3) for coating the substrate; and
-Removing the coated substrate from the receiving unit (3) by the automatic transfer mechanism (4).
19. Method according to claim 18, wherein in the step of pre-weighing the solid material to be coated on the substrate by means of a dosing unit (1), the total weight of the material transfer container (15) and the solid material to be transported in the material transfer container, measured by the weighing device (16), is defined as Wt, the material transfer container (15) is re-weighed by the weighing device (16) after feeding the solid material in the material transfer container (15) into the transport unit (2), and the measured value is Wr, then Wt-Wr is the actual material weight G fed to the transport unit 2; if the actual material weight G is within the set weight w±5%, the dosing unit (1) will continue to weigh the solid material for the next substrate, otherwise the weighing device 16 will send a signal to the control unit to mark the substrate coated at this time as "waste product".
20. The method according to claim 18 or 19, wherein after the step of removing the coated substrate from the receiving unit 3, it can be judged whether the obtained product is acceptable by a backpressure test, for example, if the backpressure of the desired product is P, and the measured backpressureThe product may be judged as a good product, otherwise the product may be judged as a bad product (waste product).
21. The method of any one of claims 18 to 20, further comprising measuring the backpressure of the substrate to be coated by a backpressure measurement device prior to the pre-weighing step, and determining the weight of the solid material to be coated on the substrate based on backpressure measurements.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN2021113507 | 2021-08-19 | ||
| CNPCT/CN2021/113507 | 2021-08-19 | ||
| PCT/CN2022/113351 WO2023020580A1 (en) | 2021-08-19 | 2022-08-18 | A coating system for coating a substrate and a method of coating the substrate with the same |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN117957361A true CN117957361A (en) | 2024-04-30 |
Family
ID=85239544
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202280061518.9A Pending CN117957361A (en) | 2021-08-19 | 2022-08-18 | Coating system for coating a substrate and method for coating a substrate using the same |
Country Status (4)
| Country | Link |
|---|---|
| EP (1) | EP4388181A1 (en) |
| KR (1) | KR20240055003A (en) |
| CN (1) | CN117957361A (en) |
| WO (1) | WO2023020580A1 (en) |
Family Cites Families (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP5597146B2 (en) * | 2010-03-18 | 2014-10-01 | 日本碍子株式会社 | Honeycomb filter manufacturing equipment |
| JP5597148B2 (en) * | 2010-03-18 | 2014-10-01 | 日本碍子株式会社 | Honeycomb filter manufacturing equipment |
| DE102012102885A1 (en) * | 2012-04-03 | 2013-10-10 | Reinhausen Plasma Gmbh | Container for powder, method for marking a container for powder and apparatus for using powder from the container |
| DE102018110804B4 (en) * | 2018-05-04 | 2024-06-27 | Umicore Ag & Co. Kg | Coated wall flow filter |
| DE102018111246A1 (en) * | 2018-05-09 | 2019-11-14 | Umicore Ag & Co. Kg | Method for coating a wall-flow filter |
| GB201911704D0 (en) * | 2019-08-15 | 2019-10-02 | Johnson Matthey Plc | Treatment of particulate filters |
-
2022
- 2022-08-18 EP EP22857891.0A patent/EP4388181A1/en active Pending
- 2022-08-18 KR KR1020247008604A patent/KR20240055003A/en unknown
- 2022-08-18 CN CN202280061518.9A patent/CN117957361A/en active Pending
- 2022-08-18 WO PCT/CN2022/113351 patent/WO2023020580A1/en active Application Filing
Also Published As
| Publication number | Publication date |
|---|---|
| WO2023020580A1 (en) | 2023-02-23 |
| EP4388181A1 (en) | 2024-06-26 |
| KR20240055003A (en) | 2024-04-26 |
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